1900 & 2400 Series PowerReel - CLUTCH ENGINEERING

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1900 & 2400 Series PowerReel Our 1900 Series and 2400 Series PowerReels handle larger and longer cables and are top-quality, low-cost alternatives to other high-capacity spring reels. These reels offer heavy-duty performance at competitive prices. 1900 and 2400 Series Reels are ideal for: Utility trucks Large cable-end accessories Aviation hangars Overhead hoists and cranes (Class A-C) Automated material handling Truck cranes and ladder trucks Standard Features E xcellent performance for industrial indoor and outdoor applications. Built to NEMA 4 standards for wet or dry environments. Heavy-duty, all-steel construction Two-piece roller guide can be repositioned to four different locations Ball stop and ratchet assembly come standard with all “Lift/Drag” models. Sealed, lifetime lubricated spring motor canister for easy and safe spring replacement A variety of ring amp ratings from 35-150 amps. 600 volt rating (1-4 conductors). 250 volts (5 or more conductors) per UL requirements. Operating range: -22O F to 220O F. CSA Certified Choosing a 1900-2400 Series Cable Reel: Use the Specification Data Sheets on pages 4-5 to determine your needs. Contact the factory for quotations. Be sure to specify enough cable - see “Cable Length Needed” on page 5. Reels are sized to handle Type SOOW-A, Type W, or Type G-GC cable. 1900 Series Reel Shown IMPORTANT If the reel will be paying out and retracting at a very high cycle rate and/or operating in an exceptionally harsh environment you may need Premium Cable - see Appendix VII, page 43 - contact Conductix-Wampfler for details. Suggested Reel Options Option Guide Rail Set Guide Rail Set Guide Rail Set Guide Rail Set Spool Lock Pivot Base Swivel Base For Other Options, see pages 20-31 Purpose To Protect Spool Flanges To Protect Spool Flanges To Protect Spool Flanges To Protect Spool Flanges To Keep the Spool From Rotating Allows reel to pivot 3600 Allows reel to swivel 3600 Details on Page: n/a n/a n/a n/a 26 24 25 Spool Size In. (mm) 19 x 5 (483 x 127) 24 x 5 (610 x 127) 19 x 8 (483 x 203) 24 x 8 (483 x 203) n/a n/a n/a Part No. 40212A 40212B 40212AA 40212BB 40260A or 40260B 40274 NEMA 4 Junction Boxes Cable Size 4 Conductor, 16-8 AWG 4 Conductor, 6-2 AWG 12 Conductor 24 Conductor 30 Conductor Cable O.D. Inches w/ 1” NPT 0.31 - 0.95 n/a 0.31 - 0.95 0.31 - 0.95 n/a Cable O.D. Inches Part No. 40923 n/a 40925A 40926A n/a w/ 1.25” NPT n/a 0.875 - 1.245 0.875 - 1.245 0.875 - 1.245 0.875 - 1.245 Cable O.D. Inches Part. No. n/a 40924 40925B 40926B 40927B w/ 1.50” NPT n/a n/a n/a 1.156 - 1.495 1.156 - 1.495 Part. No. n/a n/a n/a 40926C 40927C Visit www.conductix.us for the most current information.

1900 & 2400 Series PowerReel Dimensions 1900 Series Dimensions Dimensions A through D will vary depending on the model and can be provided with quote. 19.0 (483) E 3 1/8” to 4 1/8” depending on the model 6.5 (165) E 4.0 (101.6) 4.0 (101.6) 1.75 (44.5) 1” NPT Internal Threads 20.5 (521) 9.5 (241) 11.9 (302) 6 x 0.56 (14.22) 11.0 (279) 11.5 (292) 13.4 (340) 13.0 (330) 2400 Series Dimensions Dimensions A through D will vary depending on the model and can be provided with quote. 24.0 (610) E 3 1/8” to 4 1/8” depending on the model 6.5 (165) E 1.75 (44.5) 1.75” 4.0 (101.6) 4.0 (101.6) 1’ NPT Internal Threads 25.5 (648) 9.5 (241) 11.9 (302) 6 x 0.56 (14.22) 13.5 (279) 11.5 (292) 13.0 (330) 13.4 (340) 15 Visit www.conductix.us for the most current information.

Options and Accessories Reference Chart For your convenience, the chart below lists each series of reel, the option, and whether that option is available for that reel series. Options and accessories are described on the pages listed in the second column. Some reel models include common add-on options as standard features of the basic reel. Accessory Accessory Page Number 1200 1400 6-9 10-13 Need assistance with choosing accessories? Contact Conductix-Wampfler at 1-800-521-4888 Reel Series 1900 1500 2400 2500 Reel Series Page Number 18 14-15, 19 3200 3600 3500 16-17, 19 Ball Stops 21 Std Std * Std Std * Add-on Cable Grip 21 Add-on Add-on Add-on Add-on Add-on External Spring Tensioning Device 16 - - - - Std Flop-Over Guide Kit 13 - Add-on - - - Guide Rail Set 14 - - - Add-on Std Hand Lamps 9,13,22 Std* Add-on Add-on Add-on Add-on Junction Box 14 - - - Add-on Std Limit Switch 27 Call Call Call Add-on Add-on Marine Duty 27 - - - Call Call Pivot Base (345 ) 24 Add-on Add-on Add-on Add-on Add-on Push-Button Pendants 27 Add-on Add-on Add-on Add-on Add-on Quick-Change Spring Motor 16 - - - - Std Ratchet 26 Std Std Std Std * Add-on Receptacle Boxes 23 Std * Add-on - Add-on Add-on ReelSafe Brake 26 - Add-on Call Add-on Add-on 28-30 Std Std Std Std Std Slip Ring Assemblies (Special) 31 - Call Call Call Call Spool Lock 26 - - - Add-on Add-on Swing Mount 6 Add-on Add-on - - - Swivel Base 25 Add-on Add-on Add-on Add-on Add-on Hazardous Location Swivel Base 25 - - Add on Add-on 2500 only Add-on 3500 only Roller Guides * Selected models ONLY 20 Visit www.conductix.us for the most current information.

Ball Stops and Cable Grips Ball Stops Ball Stops, also referred to as “Cable Stops” or “Bumper Stops” are: Generally used for manually operated “Lift/Drag” applications govern retraction length. Stops are required when cable-end accessories such as hand lamps and receptacle boxes are installed on the reels. Ball stops are included with all 1200 Series reels. Ball stops are included on 1400, 1500, 1900, 2400 and 2500 Series reels “Lift/Drag” application only. Type Type A - Round with spring Type B - Split Donut For Outside Cable Dia of: inches (mm) A 0.19 to 0.44 (4.8 to 11.2) B B B C 0.44 to 0.62 (11.2 to 15.7) 0.63 to 0.75 (16.0 to 19.1) 0.75 to 1.05 (19.1 to 26.7 0.44 to 1.38 (11.2 to 15.7) For Reel Series: 1200 or 1400 only Not for 1500 Any Any Any Any Part No. 34885 34474 34475 34476 533328-K Type C - Split Round Cable Grips Also referred to as “Kellems” grips, these devices are recommended to maximize cable life. They relieve the concentrated strain on individual conductors at the cable termination point. In most installations, the eye of the cable grip is connected to an eye bolt or U-bolt. This allows free movement between the cable and the grip. Include a generous cable loop to minimize the strain on the cable. Strongly Recommended for “stretch” applications - see page 4. For Outside Cable Dia of: inches (mm) 0.43 to 0.61 (10.9 to 15.5) 0.61 to 0.74 (15.5 to 18.8) 0.74 to 0.99 (18.8 to 25.1) 0.99 to 1.24 (25.1 to 31.5) 1.25 to 1.49 (31.8 to 37.8) Part No. 03622 03623 03624 03625 03626 21 Visit www.conductix.us for the most current information.

Hand Lamps Hand Lamps provide extra lighting in applications where proper lighting is required for safety or convenience. Suitable for indoor use on all 3 conductor 16 AWG & 14 AWG cable reels. Standard on selected 1200 Series PowerReels - see page 9. Available in incandescent or fluorescent type in standard and hazardous duty models. Hand Lamps are ideal for: Manufacturing work cells Recreation centers Automotive work bays Maintenance shops School shop areas Maintenance trucks & trailers Ratchet (page 26) and ball stop (page 21) are required and may need to be ordered separately if they are not standard on the host reel. Please refer to chart on page 20. Incandescent Hand Lamp The HSR has a high impact yellow handle with recessed on/off switch and 15 amp, 125 volt outlet on the side. Features a grounded steel reflector cage with swivel hanger. Accepts up to 14/3 SJOOW-A cable. 100-watt rough service bulb not included. UL listed for indoor use. Part No. HSR Fluorescent Hand Lamp Wt lb (kg) 1.3 (.59) The FHL has rubber handles with switch and hanger. Features a plastic non-glare shield with cool operating 13-watt lamp (included). Ballast is mounted on the feeder cord. For use with 16 or 14 AWG 3 conductor SJOOW-A cable only. UL listed for indoor use. Part No. FHL Hazardous Duty Incandescent Hand Lamp Wt lb (kg) 1.2 (.55) Ideal when a hand lamp needs to be used in a hazardous location. Light-weight construction. Features non-sparking aluminum guard with full swivel hook and high impact glass reinforced phenolic handle. Resists heat up to 300o F. Accepts up to 14/3 SOOW-A cable. 100 Watt, 120 Volt. UL listed Part No. XHL Wt lb (kg) 4.9 (2.22) 22 Visit www.conductix.us for the most current information.

Hand Lamps and Receptacle Boxes Hazardous Duty Fluorescent Hand Lamp Ideal when a hand lamp needs to be used in a hazardous location. Lightweight construction. Features non-sparking plastic guard with full swivel hook and high impact glass reinforced phenolic handle. Resists heat up to 300 degrees F. Accepts 16/3 SOOW-A cable. 13 Watt, 120 Volt UL listed Part No. Wt lb (kg) 100211-PL 4.9 (2.22) Receptacle Boxes Receptacle boxes mounted to the reel cable supply mobile power where it is needed. They are standard on some models of 1200 Series reels - see page 8. They can also be wired to other PowerReels and can accommodate up to 12/3 SOOW-A cable. Receptacle Boxes are ideal for: Factory work cells Recreation centers Automotive work bays Maintenance shops School shop areas Maintenance trucks & trailers Made from a heavy duty, molded yellow thermoplastic elastomer (TPE), these boxes have an internal cord grip and are oil resistant and impervious to most chemicals. Ratchet (page 26) and Ball Stop (page 21) are required and are standard on the reels that most commonly use a receptacle box - see page 20. UL Listed and CSA approved. Description Dual 15 amp 125 volt duplex (4 outlets total) Dual 20 amp 125 volt duplex (4 outlets total) Ground Fault Circuit Interrupter (GFCI) Part No. RB RB-5-20R A Ground Fault Circuit Interrupter (GFCI) and plug assembly can be mounted onto the feeder cord of some reels. It comes standard on 1200 reels with part numbers ending in “17” - see page 8. 23 Visit www.conductix.us for the most current information.

345 Degree Pivot Base Pivot Bases allow the cable reel to pivot back and forth for alternating directions of cable payout. See part number chart below for maximum rotation. If the cable is to be paid out at more than 15 degrees away from parallel with the spool flanges, a pivot base should be used. Note that Swivel Bases are available for applications that require a full 360 degree rotation - see page 25. Pivot Bases are ordered based on the specific series of reel used - see chart below. Reel Series 1200 and 1400 1500 1900 & 2400 2500 3200 & 3600 Maximum Rotation (Degrees) 345 345 330 330 330 Part No. Wt lb (kg) PVB XPVB 40274 40274X P3-3200 7.5 (3.40) 20.0 (9.07) 43.0 (19.51) 43.0 (19.51) 103.0 (46.72) PVB Dimensions 4 x .44 Dia. Holes (11.2) 3 x 3/8”-16 UNC Tapped Holes 2.06 (52) 5.00 (127) 6.00 4.75 (152) (121) 1.19 (52) 1.62 (41) 0.38 (9.7) 1.62 (41) 0.99 (25.2) 5.75 (146) 7.00 (178) P3-3200 40274 and 40274X 14.00 14.00 REF (356) 14.00 14.00 (356) 11.50 11.50 (292) 4.31 (110) REF 4.31 2.00 (51) 2.00 9.75 (248) 9.75 REF GRIND STUD FLUSH IF IT PROTRUDES PAST BOTTOM OF BASE. Grind stud flush, if it protrudes past bottom of base. 0.75 (19) 4x 0.69 4X Ø.69 (18) 13.00 13.00 (330) 12.00 6.00 6.00 (152) .75 7.25 (184) 8.0 7.25 8.00 (203) 2 .56 (14.2) .56 24 Visit www.conductix.us for the most current information. 10.50

360 Degree Swivel Bases Swivel Bases allow reels to rotate 360 degrees in applications where continuous electrical rotation is required. They feature completely free running ball bearings in a water-tight and dust-tight enclosure. Access holes are provided for simple slip ring inspection. Hazardous duty version is available - see page 19. Standard top and side fittings: 1.0 inch NPT for cable diameters ranging from 0.50 to 0.75 inches. Contact factory regarding fittings for larger size cable. # Cond 3 4 5 6 8 10 12 1200 / 1400 Swivel Shown Amps 35 35 35 35 35 35 35 1200 and 1400 Swivel Bases Volts dim “H” Part No. 38036 600 13.5 (343) 38036B 600 13.5 (343) 38036C 250 15.0 (381) 38036D 250 15.0 (381) 38036E 250 16.5 (419) 38036F 250 16.5 (419) 38036G 250 18.5 (471) 1200 / 1400 Swivel Base Dimensions H 6.00 (152) 13.00 (330) (4) Holes .31 Dia. (7.8) 3.25 (62.6 ) 2.25 6.00 (152) 6.00 (152) (57.2 ) 3.18 (81) 1.38 (35.1) 1.38 (35.1) 6.00 (152) 7.00 (178) 1.91 (48.5) 1.63 (41.4) 1.41 (35.8) 3.18 (81) 3.25 (62.6 ) # Cond 3 4 5 6 8 10 12 1900 and 2400 Series Swivel Bases Amps Volts Part No. SM-33-PQQQ-8 35 600 SM-34-PQQQ-8 35 600 SM-35-PQQQ-8 35 250 SM-36-PQQQ-8 35 250 SM-38-PQQQ-8 35 250 SM-310-PQQQ-8 35 250 SM-312-PQQQ-8 35 250 # Cond 3 4 5 6 8 10 12 1500 Series Swivel Bases Amps Volts Part No. XSM-33-XPVB 35 600 XSM-34-XPVB 35 600 XSM-35-XPVB 35 250 XSM-36-XPVB 35 250 XSM-38-XPVB 35 250 XSM-310-XPVB 35 250 XSM-312-XPVB 35 250 25 Visit www.conductix.us for the most current information.

Optional Spool Locks, Ratchets, and Brake Spool Locks Spool Locks hold the spool in place to prevent rotation of the reel in adverse conditions or during routine maintenance. Can be included with 1900 through 3600 Series Reels. For Reel Series 1900-2400 3200-3600 Ratchets Spool Locks are used for: Part No. 40260A or 40260B (depending on reel - consult factory) 44333 Ratchets are spring activated mechanisms that temporarily lock the spool in place at selected points in the cable payout. The ratchet is released by pulling the cable. Ratchets are standard on 1900, 2400 and 2500 Series “Lift/Drag” Reels. For 3200 through 3600 Series, they need to be specified on quote/order. For Reel Series 1900-2400 3200-3600 Overhead cranes Rail cars Reel maintenance situations Ratchets are used for: Manually operated reels Lift/Drag applications - see page 4 Reels with hand lamps, receptacle boxes, or pendants installed Part No. 40251A-K or 40251B-K 43418 * * This part number is for replacement as 1900, 2400 and 2500 Series Lift/Drag reels now have ratchets included standard. ReelSafe Brake The “ReelSafe” brake (U.S. Patent # 6488224) limits the retraction speed of a spring-powered reel. This device greatly reduces the chance that an accidental uncontrolled cable retraction will occur, thereby reducing the risk of personal injury or property damage. The ReelSafe is preset at the factory to a safe speed, but it can be adjusted to the user’s preference after reel installation. Some variation in retraction rate will be noticeable during large temperature variations such as seasonal temperature change, and minor adjustments may be necessary. For Reel Series 1400 1900-2400 3200-3600 Part No. (ReelSafe Brake Unit Only *) 42900 42900 42900 * Final part number character determined upon order entry based on reel style. 26 Visit www.conductix.us for the most current information.

Other Options Limit Switches Rotary cam-type limit switches are used when an electrical interlock between cable payout length and other electrical equipment is required. These are adjustable for accurate location of the tripping mechanism. A variety of internal gear ratios are available so that the selection of the proper ratio will give maximum rotation of the actuator. The standard limit switch consists of a 2-element switch to provide 2 NO (normally open) and 2 NC (normally closed) sets of contacts in a NEMA 4 enclosure. Limit Switches are used for: Marine Duty Option Marine Duty Reels are ideal for: Marine Duty option is available for 1900 through 3600 Series PowerReels used in applications around bodies of water and other moist environments as defined by marine specifications IEEE-45 and U.S. Coast Guard specification ABS. Hardware is stainless steel, reel shaft is zinc plated, and the slip ring leads are fully sealed at both ends of the shaft. Ports and Terminals Water Treatment Plants Other Extremely Moist Areas Push Button Pendants 1900 through 3600 Series Reels Pendant Switches Overrun Control Limit Switches Contact Factory for Consultation Limit Switches Contact Factory for Consultation Part No. To be Determined Part No. To be Determined Cable reels can be used to manage pendant cables and the push button pendant on the cable end. Conductix-Wampfler offers a complete line of ergonomically designed push button pendants - From 2 to 24 buttons. Contact Conductix-Wampfler Sales and ask for the Pendant Catalog (CAT1001) or download it from www.conductix.us 27 Visit www.conductix.us for the most current information.

Roller Guides, Type “A” Conductix-Wampfler includes a 4 roller guide as a standard item on each spring driven cable reel. For special cable payout applications, we recommend our Type C - page 29. Type “A” Roller Guides are used to: Centering the cable on the spool Single-direction stretch applications Lift Applications Providing a “seat” for a Ball Stop Payouts not more than 15 degrees from tangent to the drum IMPORTANT NOTE: Do not use the standard rigid mount roller guide supplied with reel in a two-way payout application. Refer to pages 29-30 for Appropriate Options. Maximum Cable O.D. inches (mm) 1.25 (32) 2.00 (51) Roller Guide Part No. A2 A3A # A2 Four Roller Guide # AA Guide Mount Set (Used on 3” or greater drum widths). Tapped for 3/8-16NC Screw 1.281 (32.5) 3.38 (114) 1.25 (31.8) Roller Guide Mounting Set Part No. (for old E, F, H, and M Style Reels) AA 08397Z Clearance Hole For 3/8-16NC Screw 3.38 (85.7 0.88 (22.2) 3.688 (94) 2.44 (62) 1.5 (38) 1.66 (42.1) 1 9/16 (40) 2.281 (22.2) 2.0 (50.8) 2.44 (62) 2.91 (74) 36 Serrations @ 45 # A3A Four Roller Guide # 08397Z Cable Guide Support (Used on 2.5” or less drum widths). TAPPED FOR 3/8-16NC 1.63 (41.3) Clearance Hole For 3/8-16NC Screw 1.25 (31.8) 1.81 (46) 3 11/16 4.38 (111) 3.56 (90.5) 2.44 (46) 2.31 (58.7) 2.19 (55.6) 1.63 (41.3) 3.06 (78) 0.88 Dia (22.2) 2.91 (73.1) 1.000 (25.4) Variable 28 Visit www.conductix.us for the most current information.

Roller Guides, Type “C” The rugged “Type C” guide mounts separate from the reel. Suitable for all PowerReel cable reels. Features sealed ball bearings Comes in standard matte black finish Type “C” Roller Guide (Two-Way Version) is ideal for: Cable that pays out in two directions and is terminated at the center of travel When a structural member or obstruction would interfere with the normal payout and retraction of the cable Bend Diameter Max. Cable O.D. inches (mm) 12 (305) 1.0 (25.4) 18 (457) 1.5 (38.1) 24 (610) 2.0 (50.8) 12 (305) 1.0 (25.4) 18 (457) 1.5 (38.1) 24 (610) 2.0 (50.8) Type Two-Way Payout Two-Way Payout Two-Way Payout Single Sheave Single Sheave Single Sheave Two-Way Payout Shown Part No. C12S C18S C24S CA11397 CA11518 CA11199 IMPORTANT NOTE: When using roller guides premium cable will be required. See Appendix VII, page 43, and contact the factory for details. # C12S Roller Guide (# CA11397 Has just one 12” sheave) 5.25 (133) 2.5 (64) 12.0 (305) 6.50 (165) 4 x 0.56 holes (14.2) 13.75 Dia (349) 15.0 (381) 12.0 Dia (305) 1.13 (28.7) 14.0 (356) 3.50 (89) 17.0 (432) 27.7 (704) # C18S Roller Guide (# CA11518 has just one 18” sheave) 16.00 16.0 (406) 12.00 2.0 (50.8) 12.0 (305) 6.84 9.5 6.84 (174) (241) 12.0 Dia (305) 9.50 4 x 0.56 holes (14.2) 41.38 (1051) 41.38 10.75 (273) 20.9 (531) 20.9 18.0 Dia (457) Ø18 10.44 (265) 10.44 (265) 24.0 (610) 10.44 10.44 24 Visit www.conductix.us for the most current information. 1.82 (46) 2.57 (65) 29

Roller Guide Installation Configuration A Low lift height to the center line of reel. No obstructions to nominal catenary of cable. Secondary roller guide is not needed. Configuration B There is an obstruction to the normal catenary of the cable between the lift height center line and the lay of the cable. There is also adequate space between reel flange and cable lay for two-way payout roller guide (Part No. C12S, C18S or C24S - page 29) 4’ max. 4’ max. Max. Allowable Q Front View (A) Q Side View (B) Space window available will vary depending on reel and guide mounting position - contact the factory. Selection of Roller for Configuration B 1) Determine the bend diameter required. The bend diameter (sheave diameter) should be no less than 10 times the cable diameter to maximize cable life. 2) Select roller guide with required bend diameter (from page 29). Lay out cable reel and roller guide to assure that there is no interference. When in doubt as to which configuration applies, lay out the application using configuration B. 3) Specify catalog number of roller guide and note on the order, “For separate mounting with cable reel part number.” If the cable reel is not on the same order, refer to the cable reel order or specify the cable that will run on the roller guide. Mounting for Configuration B F ront View (A): Locate center line of the roller guide on the mean center line of the spool flange to obtain a vertical line payout of cable from the spool to the roller guide when the spool is one half full. Side View (B): Align the roller guide center line with spool center line. NOTE: Allow a maximum of 4 feet from spool horizontal center line to the surface supporting the cable. 30 Visit www.conductix.us for the most current information.

Custom Roller Guides and Slip Ring Options Custom Roller Guides Conductix-Wampfler manufactures a variety of custom roller guides designed for specific applications. These are usually mounted separately from the reel to guide cables through floors, decks, and around obstacles. The guide at the left is an example of a robust, custom cable guide - Part No. 46976. This unit has a roughly 9” (229 mm) box with a 3.6” (91 mm) square opening between the rollers. It is used to guide a cable through the deck of a crane or similar machine. Note that the “A3A” guide shown on page 28 can also be remotely mounted and used in a similar manner. Contact us to discuss your application! Slip Ring Options Conductix-Wampfler offers a complete line of standard and custom engineered slip rings for use with a wide variety of industrial machinery. We have over 60 years of experience in slip ring design and can offer many alternate styles of slip rings for custom applications. For some reeling cable applications, a special slip ring treatment may be required. We can also integrate fiber optic swivels with the basic electric slip ring assembly. We can also incorporate other devices such as rotary cam switches, position encoders, and so forth. Contact Conductix-Wampfler with your application or problem - we have the solution! Slip Ring Features Precision machined copper alloy rings with copper graphite brushes for power applications. Silver-plated rings and silver graphite brushes for low-level signal applications. Gold-plated rings and gold contact brushes for low-level signal applications (DMX, ethernet, video, etc.)   Combination rings for power, control and signal level circuits. Single or redundant double brushes. A wide range of enclosure styles and bore sizes. 31 Visit www.conductix.us for the most current information.

Visit www.conductix.us for the most current information. 1900 & 2400 Series PowerReel Suggested Reel Options For Other Options, see pages 20-31 Our 1900 Series and 2400 Series PowerReels handle larger and longer cables and are top-quality, low-cost alternatives to other high-capacity spring reels. These

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